Summary – a complex 15 month design and build contract with global food production business Kerry Foods. Construction of a new 23,000ft2 food production factory, along with the simultaneous demolition of an existing brick facility, without disrupting on-going food production.
Construction in an exacting environment
The factory envelope would be erected to span between two existing buildings, which were neither parallel nor level, straddling over the existing obsolete production building. The challenge was to make this change whilst production continued in the midst of the work – and in this case production meant food, and the demanding hygienic standards that go with it. Health and Safety was paramount, Kerry employ over 300 people on site, working continuously during construction, our in-house H&S officer was on site permanently liaising closely with Kerry management and monitoring all activities during construction.
24 hour flexibility
Kerry’s own client’s demands frequently changed, therefore our planning and designs were constantly adapted to accommodate. At times our staff worked 24-hour shifts to allow food production to be maintained. The new unit was erected over the top of the existing brick clad building and then partitioned with a temporary steel wall so that one of the clients main food processing units could remain in production on one side of the wall whilst an old brick and asbestos riddled building was demolished and removed from the other side.
Food safety and the risk of contaminati on were of critical importance, particularly with demolition and HSE notifiable removal of asbestos. Additional work to the existing food distribution unit, the erection of a new engineering block, laboratory, and in particular a stainless steel production mezzanine floor within the new factory also took place during construction. Once the existing brick building was demolished, work continued on the new unit, including the installation of specialist ‘hathenware’ drainage with stainless steel channels, the food-safe resin fl oor and mezzanine amenities floor with room for over 150 lockers and toilets. As demands upon Kerry’s production significantly increased we then facilitated the design and erection of a 3,700ft 2 stainless steel mezzanine production floor ‘retrofitted’ into the new building.
”A fantastic achievement under incredibly testing conditions”